Fault code and repair instruction AS-Tronic for EvoBus with Softwareversion V33_4g status:2005-08

EvoBus type of error

EvoBus path of

responsibility
ZF-failure No.

failure
cause of failure/
fault description repair instruction
component

12 20 ZF lower part of TCU Short circuit to ground at output stage to Y2 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
2
(Valve Splitter) oil / water.
13 20 ZF lower part of TCU Short circuit to ground at output stage to Y3 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
3 (Valve Splitter) oil / water.
14 20 ZF lower part of TCU Short circuit to ground at output stage to Y4 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
4
(Valve Select) oil / water.
15 20 ZF lower part of TCU Short circuit to ground at output stage to Y5 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
5
(Valve Select) oil / water.
16 20 ZF lower part of TCU Short circuit to ground at output stage to Y6 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
6
(Valve Shift) oil / water.
17 20 ZF lower part of TCU Short circuit to ground at output stage to Y7 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
7
(Valve Shift) oil / water.
18 20 ZF lower part of TCU Short circuit to ground at output stage to Y8 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
8
(Valve Range) oil / water.
19 20 ZF lower part of TCU Short circuit to ground at output stage to Y9 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
9
(Valve Range) oil / water.
10 20 ZF lower part of TCU Short circuit to ground at output stage to Y10 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
10
(Main valve) oil / water.
11 20 ZF lower part of TCU Short circuit to ground at output stage to Y1 according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
17
(inertia brake valve) oil / water.
42 20 ZF transmission actuator Short circuit to ground at output stage to Y17 quantify the Ohm coefficient on the 18- pole plug of the clutch actuator between pin 9 and 16, in case coefficient is < 15 Ohm, exchange clutch actuator. ZF
18 clutch actuator (Valve clutch disengage slow) No. 0501 212 475
40 20 ZF transmission actuator Short circuit to ground at output stage to Y15 quantify the Ohm coefficient on the 18- pole plug of the clutch actuator between pin 7 and 16, in case coefficient is < 15 Ohm, exchange clutch actuator. ZF
19
clutch actuator (Valve clutch engage slow) No. 0501 212 475
43 20 ZF transmission actuator Short circuit to ground at output stage to Y16 quantify the Ohm coefficient on the 18- pole plug of the clutch actuator between pin 12 and 17, in case coefficient is < 15 Ohm, exchange clutch actuator. ZF
20 clutch actuator (Valve clutch disengage fast) No. 0501 212 475
41 20 ZF transmission actuator Short circuit to ground at output stage to Y14 quantify the Ohm coefficient on the 18- pole plug of the clutch actuator between pin 8 and 17, in case coefficient is < 15 Ohm, exchange clutch actuator. ZF
21 clutch actuator (Valve clutch engage fast) No. 0501 212 475
54 20 ZF / EvoBus transmission actuator, Short circuit to ground at output ADVP or remove plug from transmission output speed sensor, if short circuit is due to the transmitter continuation of the journey is possible with manual mode and failure
transmission output speed ADVP1 (wakeup control signal for output No. 99, exchange transmitter, if necessary check other components (in case of existent) on ADVP 1 (pin 11)
sensor; in case no diode speed sensor; in case of existent and no diode
22 installed: E-module, display, installed: E-module, voltage supply to display,
warning lamp, buzzer warning lamp, warning buzzer)

55 20 ZF / EvoBus E- module/ electrical system of Short circuit to ground at output stage to wiring, check warning lamp (at 300 series with ZF diplay; at 400 / Travego series, the failure will not appear)
23
vehicle warning lamp (E- Module)

page 1 von 13 created by: BKS-R Schekle, BKS-I Stoll

 Fault code and repair instruction AS-Tronic for EvoBus with Softwareversion V33_4g status:2005-08

EvoBus type of error

EvoBus path of

responsibility
ZF-failure No.

failure
cause of failure/
fault description repair instruction
component

56 20 ZF / EvoBus transmission actuator plug/ short circuit to ground at output SD to display check 18 pole plug/ display plug or electrical system of vehicle (at 300 series with ZF diplay; at 400 / Travego series, the failure will not appear)
25 electrical system of vehicle

88 42 EvoBus vehicle computer CAN signal error "engine configuration quantify resistance between CAN H and L: ought to be 60 ohm, if necessary pay attention to other CAN errors, check CAN wiring and plug, check error
message" (engine configuration). Engine memory of on-board computer.
27 controller sends a faulty signal via CAN.

83 42 ZF Intarder CAN signal error "Actual driveline retarder- Accomplish Datalogger measurement (Intarder) at standstill:
percent torque" signal (ERC1_DR) Intarder With momentary rising of the output speed at engine start (vehicle stand still) detectable, it's necessary to check the output stage to the tacho and GIV
28 ECU sends incorrect signal via CAN. respectively.
Quantify resistance between CAN H and L: ought to be 60 ohm, if necessary pay attention to other CAN errors, check CAN wiring and plug, check error
memory of Intarder, if necessary exchange Intarder ECU.
84 42 ZF Intarder CAN signal error "Engine coolant load quantify resistance between CAN H and L: ought to be 60 ohm, if necessary pay attention to other CAN errors, check CAN wiring and plug, check error
increase" signal (ERC1 DR). Intarder memory of Intarder, if necessary exchange Intarder ECU.
29 electronic sends a faulty signal via CAN.

94 42 EvoBus On board computer (FR), CAN CAN signal error "Actual engine retarder - quantify resistance between CAN H and L: ought to be 60 ohm, if necessary pay attention to other CAN errors, check CAN wiring and plug, check error
signal or connection percent torque" signal (ERC1_ER). On-board memory of on-board computer.
31 computer sends a faulty signal via CAN.

12 22 ZF lower part of TCU Interruption at output stage to Y2 (Valve according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
34 Splitter) oil / water.
13 22 ZF lower part of TCU Interruption at output stage to Y3 (Valve according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
35
Splitter) oil / water.
14 22 ZF lower part of TCU Interruption at output stage to Y4 (Valve according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
36
Select) oil / water.
15 22 ZF lower part of TCU Interruption at output stage to Y5 (Valve according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
37
Select) oil / water.
16 22 ZF lower part of TCU Interruption at output stage to Y6 (Valve Shift) according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
38
oil / water.
17 22 ZF lower part of TCU Interruption at output stage to Y7 (Valve Shift) according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
39
oil / water.
18 22 ZF lower part of TCU Interruption at output stage to Y8 (Valve according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
40
Range) oil / water.
19 22 ZF lower part of TCU Interruption at output stage to Y9 (Valve according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
41
Range) oil / water.
10 22 ZF lower part of TCU Interruption at output stage to Y10 (Main according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
42
valve) oil / water.

page 2 von 13 created by: BKS-R Schekle, BKS-I Stoll

 Fault code and repair instruction AS-Tronic for EvoBus with Softwareversion V33_4g status:2005-08

EvoBus type of error

EvoBus path of

responsibility
ZF-failure No.

failure
cause of failure/
fault description repair instruction
component

11 22 ZF lower part of TCU Interruption at output stage to Y1 (inertia brake according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
49
valve) oil / water.
42 22 ZF transmission actuator Interruption at output stage valve Y17 (clutch test the 18 pole clutch actuator plug between pin 9 and 16 for interruption ( Ohm coefficient approx. 16Ω), if okay exchange transmission actuator / if not okay
50
clutch actuator disengage slow) exchange clutch actuator
40 22 ZF transmission actuator Interruption at output stage valve Y15 (clutch test the 18 pole clutch actuator plug between pin 7and 16 for interruption ( Ohm coefficient approx. 16Ω), if okay exchange transmission actuator / if not okay
51
clutch actuator engage slow) exchange clutch actuator
43 22 ZF transmission actuator Interruption at output stage valve Y16 (clutch test the 18 pole clutch actuator plug between pin 12 and 17 for interruption ( Ohm coefficient approx. 16Ω), if okay exchange transmission actuator / if not okay
52
clutch actuator disengage fast) exchange clutch actuator
41 22 ZF transmission actuator Interruption at output stage to large Y14 test the 18 pole clutch actuator plug between pin 8 and 17 for interruption ( Ohm coefficient approx. 16Ω), if okay exchange transmission actuator / if not okay
53
clutch actuator (clutch engage fast) exchange clutch actuator
54 22 ZF / EvoBus output speed sensor interruption at output ADVP or ADVP1 Check, if the diode V1, V2 and wiring are installed. If not, remove 35 pole E- module plug and measure voltage between pin 2 and 18 (ought to be 24 V); if
transmission/ main wiring (voltage supply to output speed sensor voltage okay exchange E- module otherwise check more components, which are attached between pin 2 (E- module) and pin 11 (ADVP), exchange them if
54 transmission/ electrical system transmission, CAN bridge; in case of existent: necessary; measure voltage at the transmissionsided output speed sensor plug between pin 1 and 2 (ought to be 24 V) if voltage okay change sensor, if
of vehicle E- module, display, warning lamp etc.) voltage not okay test transmission main wiring pin 18 to 1or 6 to 2 for interruption.

55 22 ZF / EvoBus E- module/ electrical system of Interruption at output stage to warning lamp (E-output (-), check cable joint between pin 33 (35 pole E- module plug) and warning lamp, if okay exchange E- module (at 300 series with ZF diplay; at 400 /
55
vehicle module) Travego series, the failure will not appear)
12 21 ZF transmission actuator Short circuit to positive at output stage to according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
66 valve Y2 (splitter group) oil / water.
13 21 ZF transmission actuator Short circuit to positive at output stage to according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
67 valve Y3 (splitter group) oil / water.
14 21 ZF transmission actuator Short circuit to positive at output stage to according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
68 valve Y4 (Selection valve) oil / water.
15 21 ZF transmission actuator Short circuit to positive at output stage to according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
69 valve Y5 (Selection valve) oil / water.
16 21 ZF transmission actuator Short circuit to positive at output stage to according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
70 valve Y6 (Shift valve) oil / water.
17 21 ZF transmission actuator Short circuit to positive at output stage to according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
71 valve Y7 (Shift valve) oil / water.
18 21 ZF transmission actuator Short circuit to positive at output stage to according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
72
valve Y8 (Range change group low) oil / water.
19 21 ZF transmission actuator Short circuit to positive at output stage to according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
73
valve Y9 (Range change group high) oil / water.
10 21 ZF transmission actuator Short circuit to positive at output stage to according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
74 valve Y10 (Main valve) oil / water.

page 3 von 13 created by: BKS-R Schekle, BKS-I Stoll

 Fault code and repair instruction AS-Tronic for EvoBus with Softwareversion V33_4g status:2005-08

EvoBus type of error

EvoBus path of

responsibility
ZF-failure No.

failure
cause of failure/
fault description repair instruction
component

11 21 ZF transmission actuator Short circuit to positive at output stage to according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006 or exchange the valve body 0501 321 147. Check air system for dirt /
81 valve Y1 (inertia brake valve) oil / water.
42 21 ZF clutch actuator/ upper part of Short circuit to positive at output stage to test the 18 pole transmission actuator plug to the clutch actuator between pin 9/11/15/10/7/8/12 and pin 18 (ADVP 24V plus) for short circuit, if there is a short
82 TCU valve Y17 (clutch disengage slow) circuit exchange clutch actuator ZF No. 0501 212 475. If there is no short circuit then exchange upper part of TCU ZF No. 6009 098 002 (Rep.kit) with vehicle
specific programming.
40 21 ZF clutch actuator Short circuit to positive at output stage to test the 18 pole transmission actuator plug to the clutch actuator between pin 7/11/15/10/9/8/12 and pin 18 (ADVP 24V plus) for short circuit, if there is a short
83 valve Y15 (clutch engage slow) circuit exchange clutch actuator ZF No. 0501 212 475. If there is no short circuit then exchange upper part of TCU ZF No. 6009 098 002 (Rep.kit) with vehicle
specific programming.

43 21 ZF clutch actuator Short circuit to positive at output stage to test the 18 pole transmission actuator plug to the clutch actuator between pin 12/11/15/10/7/8/9 and pin 18 (ADVP 24V plus) for short circuit, if there is a short
84 valve Y16 (clutch disengage fast) circuit exchange clutch actuator ZF No. 0501 212 475. If there is no short circuit then exchange upper part of TCU ZF No. 6009 098 002 (Rep.kit) with vehicle
specific programming.
41 21 ZF clutch actuator Short circuit to positive at output stage to test the 18 pole transmission actuator plug to the clutch actuator between pin 8/11/15/10/7/9/12 and pin 18 (ADVP 24V plus) for short circuit, if there is a short
85 valve Y14 (clutch engage fast) circuit exchange clutch actuator ZF No. 0501 212 475. If there is no short circuit then exchange upper part of TCU ZF No. 6009 098 002 (Rep.kit) with vehicle
specific programming.
54 21 ZF / EvoBus output speed sensor short circuit to positive at output ADVP or Check, if the diode V1, V2 and wiring are installed. If not, remove 35 pole E- module plug and measure voltage between pin 2 and 18 (ought to be 24 V); if
transmission/ main wiring ADVP1 (voltage supply to output speed voltage okay exchange E- module otherwise check more components, which are attached between pin 2 (E- module) and pin 11 (ADVP), exchange them if
86 transmission/ electrical system sensor 1 and other external electrical necessary; measure voltage at the transmissionsided output speed sensor plug between pin 1 and 2 (ought to be 24 V) if voltage okay change sensor, if
of vehicle components) voltage not okay test transmission main wiring pin 18 to 1or 6 to 2 for interruption.

55 21 ZF / EvoBus E- module/ electrical system of Short circuit to positive at output stage to output is connected to ground, check cable joint between pin 33 (35 pole E- module plug) and warning lamp, if okay exchange E- module
87 vehicle warning lamp ( E- module)
56 21 ZF / EvoBus clutch actuator/ electrical Short circuit to positive at output SD to ZF loosen the plug at the ZF display, test display plug pin 4 against pin 8 for short circuit to positive, if there is a short circuit exchange display, loosen vehiclesided
89 system of vehicle display 18 pole transmission actuator plug, check pin 9 against pin 11/1/4/5 within the plug, when short circuit check vehiclesided wiring , if necessary refurbish it.

66 40 ZF upper part of TCU Communication error between controller 1 and disconnect main electric current supply or ignition, if error is still existent undertake programming again, if necessary exchange upper part of TCU ZF No. 6009
90 controller 2 (ECU failure) 098 002 (Rep.kit), vehicle specific programming must be installed.

79 42 EvoBus ABS / EBS brake control Vehicle-CAN error on "ABS active" signal check CAN lines, plug connections, ohm coefficient (ought to be 60 Ω)
92 (EBC1)
80 42 EvoBus ABS / EBS brake control Vehicle-CAN error on "ASR engine control check CAN lines, plug connections, ohm coefficient (ought to be 60 Ω)
93 active" signal (EBC1)
99 42 EvoBus on- board computer CAN error on "Cruise control active" signal check CAN lines, plug connections, ohm coefficient (ought to be 60 Ω)
95 (CCVS)

89 42 EvoBus on- board computer CAN error on "Cruise control set speed" check CAN lines, plug connections, ohm coefficient (ought to be 60 Ω)
96 (CCVS)

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 Fault code and repair instruction AS-Tronic for EvoBus with Softwareversion V33_4g status:2005-08

EvoBus type of error

EvoBus path of

responsibility
ZF-failure No.

failure
cause of failure/
fault description repair instruction
component

90 42 EvoBus on- board computer CAN error on "Engine speed" signal (EEC1) check engine speed sensor or signal flux to on- board computer
97

34 42 ZF lower part of TCU ZF signal error on transmission input speed The diagnostic code will be partly set at engine stall → driving error.
signal Check the counting disc; Backlash up to 3mm is acceptable; is the counting disc spinning loose, check the fit of the counting disc; No conspicuity at counting
98 disc detectable and according to frequency of occurence, exchange lower part of TCU ZF No. 6009 298 006, or exchange the internal wiring ZF No. 0501 321
146 of transmission actuator.
35 42 ZF output speed sensor/ electrical ZF signal error on output speed signal 1 Check 24 V voltage supply at the output speed sensor plug between pin 18 and pin 6. Test signal flux between pin 11 at the 18 pole plug of the transmission
99 system of transmission main wiring and pin 4 at the output speed sensor plug for passing;
Check the software version and if necessary update to the latest version.
36 42 EvoBus / ZF ABS brake control / output CAN error on output speed signal 2 check CAN signal "speed of rear axle". Signal checkup from vehicle CAN via CAN bridge to transmission actuator; if necessary exchange the tacho sensor.
100 speed sensor / ECU Check the software version and if necessary update to the latest version.

37 42 ZF / EvoBus output speed sensor / electrical Error on both output speed signals: ZF signal check CAN signal "speed of rear axle". Signal checkup from vehicle CAN via CAN bridge to transmission actuator; if necessary exchange tacho sensor;
system of transmission / ABS error "output speed signal 1" and CAN signal exchange of transmission output speed sensor, check 24 V voltage supply at the output speed sensor plug between pin 18 and pin 6. Test signal flux between
101 brake control error "output speed signal 2" pin 11 at the 18 pole plug of the transmission main wiring and pin 4 at the output speed sensor plug for good connection.
Check the software version and if necessary update to the latest version.
34 41 ZF output speed sensor/ electrical Plausibility error between transmission input check CAN signal "speed of rear axle". Signal checkup from vehicle CAN via CAN bridge to transmission actuator; exchange of transmission output speed
system of transmission / speed and out- put speed sensor; check 24 V voltage supply at the output speed sensor plug between pin 18 and pin 6. Test signal flux between pin 11 at the 18 pole plug of the
102 transmission actuator transmission main wiring and pin 4 at the output speed sensor plug for good connection. As the case may be input speed error, sensor problem (internal wiring
of transmission actuator ZF No. 0501 321 146) or value fault (upper part of TCU)

59 23 EvoBus electrical system of vehicle High voltage (Vehicle electrical system check vehicle supply voltage, ought to be 19,5 - 29,5V, check battery power and ignition voltage.
104 voltage too high)
59 24 EvoBus electrical system of vehicle Low voltage (Vehicle electrical system voltage check vehicle supply voltage, ought to be 19,5 - 29,5V, check battery power and ignition voltage.
105 too low)
44 24 ZF actuator Stabilised voltage supply at output AU (clutch loosen the 18 pole transmission actuator plug, measure voltage between pin 15 and 2 (ought to be 4,6 - 5,8V), if okay exchange clutch actuator ZF No. 0501
107 sensor supply) out of valid range 212 475, if not okay exchange upper part of TCU ZF No. 6009 098 002 (Rep.kit) with suitable vehicle specific programming

page 5 von 13 created by: BKS-R Schekle, BKS-I Stoll

 Fault code and repair instruction AS-Tronic for EvoBus with Softwareversion V33_4g status:2005-08

EvoBus type of error

EvoBus path of

responsibility
ZF-failure No.

failure
cause of failure/
fault description repair instruction
component

57 41 ZF / EvoBus speed range selector / electrical Speed range selector with rotary switch (old Loosen 35 pole plug at the E- module !
system of vehicle / e-module speed range selector with seperate e-module): selector lever position:
Error in selector lever or tip lever good connection between pin 17 and between R N D
pin 29: good no no
pin 11: no good no
pin 8 : no no good

tip lever position:

good connection between pin 17 and between reset position manual/ upshift downshift
108a
automatic
pin 7 : good good no no
pin 25: no good no no
pin 26: no no no good
pin 28: no no good no

Check the plug towards the vehicle wiring for oxidation.

57 41 ZF Speed range selector Speed range selector without rotary switch Check the speed range selector version, should be V14, exchange if necessary.
(new speed range selector with integrated e-
108b module):
Error in selector lever or tip lever
65 3 ZF / EvoBus E- module/ electrical system of ZF CAN timeout Exchange E- module (old speed range selector) / speed range selector (new), check ZF CAN wiring:
vehicle When old speed range selector with seperate e-molule mounted: check good connection between 35 pole E- module plug and 18 pole transmission actuator
plug. Pin 20 CAN H (e- module) to pin 3 (transmission actuator) / pin 3 (e- module) to pin 6 (transmission actuator 3)
When new speed range selector with integrated e-module mounted: check good connection between speed range selector plug and 18 pole transmission
110 actuator plug. Pin 3 CAN H (speed range selector) towards pin 3 (transmission actuator) / pin 1 (speed range selector) towards pin 6 (transmission actuator).
In very few cases the transmission actuator is the failure reason and has to be changed in last action.

45 33 ZF / EvoBus transmission / clutch clutch engaged unintentionally in standstill, check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212 475; check length of tappet (ought to be
gear engaged 119mm depending on application);check disengagement and lubrication of contact areas declutching bearing/ release fork, lubricate if necessary; check
114 configuration of pressure plate/ driving disc according to customer's specification.
Only in very few cases the exchange of the clutch actuator will be a corrective of the failure. Before a exchange of clutch parts, it's well to fit a new clutch
actuator temporary. Is this not a corrective action, fit back the old clutch actuator.
44 25 ZF transmission / clutch Error in clutch self - adjustment process Is declutching bearing engaged / broken? Check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212
475; check length of tappet (ought to be 119mm depending on application); check configuration of pressure plate/ driving disc according to customer's
117 specification. Check spigot bearing within the fly- wheel; if error occurs immediately after ignition is activated, exchange upper part of TCU ZF No. 6009 098
002 (Rep.kit)

page 6 von 13 created by: BKS-R Schekle, BKS-I Stoll

 Fault code and repair instruction AS-Tronic for EvoBus with Softwareversion V33_4g status:2005-08

EvoBus type of error

EvoBus path of

responsibility
ZF-failure No.

failure
cause of failure/
fault description repair instruction
component

45 31 ZF transmission / clutch clutch does not disengage Check system air pressure for clutch actuator (ought to be 7 - 12 bar); Check the pressure reduction valve, exchange the valve in case of leakage; Check the
tranmission sided air circuit for dirt comtamination. if necessary exchange clutch actuator ZF No. 0501 212 475 or repair with repair kit ZF-No. 0501 322 365; Is
118 declutching bearing engaged / broken? Check length of tappet (ought to be 119mm depending on application); check configuration of pressure plate/ driving
disc according to customer's specification. Check spigot bearing within the fly- wheel; if error occurs immediately after ignition is activated, exchange upper part
of TCU ZF No. 6009 098 002 (Rep.kit).
45 32 ZF transmission / clutch clutch does not engage/ does not transmit Is declutching bearing engaged / broken? Check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212
engine torque 475; check length of tappet (ought to be 119mm depending on application); check configuration of pressure plate/ driving disc according to customer's
119 specification. Check spigot bearing within the fly- wheel; if error occurs immediately after ignition is activated, exchange upper part of TCU ZF No. 6009 098
002 (Rep.kit)
42 33 ZF clutch actuator Mechanical failure of Y17 (slow Is declutching bearing engaged / broken? Check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212
120 disengagement clutch valve) 475; check length of tappet (ought to be 119mm depending on application); exchange upper part of TCU if necessary ZF No. 6009 098 002 (Rep.kit)

43 33 ZF clutch actuator Mechanical failure of Y16 (fast disengagement Is declutching bearing engaged / broken? Check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212
121 clutch valve) 475; check length of tappet (ought to be 119mm depending on application); exchange upper part of TCU if necessary ZF No. 6009 098 002

40 33 ZF clutch actuator Mechanical failure of Y15 (slow engagement Is declutching bearing engaged / broken? Check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212
122 clutch valve) 475; check length of tappet (ought to be 119mm depending on application); exchange upper part of TCU if necessary ZF No. 6009 098 002 (Rep.kit)

41 33 ZF clutch actuator Mechanical failure of Y14 (fast engagement Is declutching bearing engaged / broken? Check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212
123 clutch valve) 475; check length of tappet (ought to be 119mm depending on application); exchange upper part of TCU if necessary ZF No. 6009 098 002 (Rep.kit)

44 42 ZF clutch actuator Error on clutch travel signal Is declutching bearing engaged / broken? Check system air pressure for clutch actuator (ought to be 7 - 12 bar); exchange clutch actuator ZF No. 0501 212
475; check length of tappet (ought to be 119mm depending on application); check configuration of pressure plate/ driving disc according to customer's
124 specification. Check spigot bearing within the fly- wheel; check counting disc for close fit and normal function (demounting of transmission actuator is
necessary); if error occurs immediately after ignition is activated, exchange upper part of TCU ZF No. 6009 098 002 (Rep.kit)

27 42 ZF upper part of TCU Error on pressure sensor signal Check air supply towards transmission actuator (7-12 bar). Internal voltage problem at the pressure sensor inside the transmission actuator, according to
126 frequency of occurence exchange upper part of TCU ZF No. 6009 098 002 (Rep.kit)
28 42 ZF upper part of TCU Error on ECU temperature sensor signal internal voltage problem at the temperature sensor inside the transmission actuator, according to frequency of occurence exchange upper part of TCU ZF No.
127 6009 098 002 (Rep.kit)
30 21 ZF lower part of TCU Short circuit to positive of shift sensor (main according to frequency of occurence, check the lower part of transmission actuator, refurbish by component exchange (see attachment) or if necessary
129 transmission) exchange complete lower part of transmission actuator ZF No. 6009 298 006.
30 20 ZF transmission actuator Short circuit to ground of shift sensor (main according to frequency of occurence, check the lower part of transmission actuator, refurbish by component exchange (see attachment) or if necessary
130 transmission) exchange complete lower part of transmission actuator ZF No. 6009 298 006.

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 Fault code and repair instruction AS-Tronic for EvoBus with Softwareversion V33_4g status:2005-08

EvoBus type of error

EvoBus path of

responsibility
ZF-failure No.

failure
cause of failure/
fault description repair instruction
component

30 22 ZF transmission actuator Interruption of shift sensor (main transmission) according to frequency of occurence, check the lower part of transmission actuator, refurbish by component exchange (see attachment) or if necessary
131
exchange complete lower part of transmission actuator ZF No. 6009 298 006.
30 25 ZF transmission actuator / Self adjustment error of shift sensor (main check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal diameter (9mm);
transmission transmission) piston rod of main transmission not engaged after exchange of transmission actuator; check end position value (end position_gears_even/uneven) 530- 580/80-
132 120. The error is situated in the main transmission if the values lie outside this range. If error occurs sporadically, check the lower part of transmission actuator,
refurbish by component exchange (see attachment) or if necessary exchange complete lower part of transmission actuator ZF No. 6009 298 006.

31 21 ZF transmission actuator Short circuit to positive of gate select sensor according to frequency of occurence, check the lower part of transmission actuator, refurbish by component exchange (see attachment) or if necessary
133 (main transmission) exchange complete lower part of transmission actuator ZF No. 6009 298 006.
31 20 ZF transmission actuator Short circuit to ground of gate select sensor according to frequency of occurence, check the lower part of transmission actuator, refurbish by component exchange (see attachment) or if necessary
134 (main transmission) exchange complete lower part of transmission actuator ZF No. 6009 298 006.
31 22 ZF transmission actuator Interruption of gate select sensor (main according to frequency of occurence, check the lower part of transmission actuator, refurbish by component exchange (see attachment) or if necessary
135 transmission) exchange complete lower part of transmission actuator ZF No. 6009 298 006.
31 25 ZF transmission actuator, Self adjustment error of gate select sensor check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal diameter (9mm);
transmission (main transmission) check end position value: (Anschlag_gasse_1/2 is:10/12 gear transmission gate R/1) ought to be 70-120 (end position_gate_3/4 is: 10/12 gear transmission
136 gate 2/3) ought to be 500-580; The error is situated in the main transmission if the values lie outside this range. If error occurs sporadically, check the lower part
of transmission actuator, refurbish by component exchange (see attachment) or if necessary exchange complete lower part of transmission actuator ZF No.
6009 298 006.
32 21 ZF transmission actuator Short circuit to positive of range change group according to frequency of occurence, check the lower part of transmission actuator, refurbish by component exchange (see attachment) or if necessary
137 sensor exchange complete lower part of transmission actuator ZF No. 6009 298 006.
32 20 ZF transmission actuator Short circuit to ground of range change group according to frequency of occurence, check the lower part of transmission actuator, refurbish by component exchange (see attachment) or if necessary
138
sensor exchange complete lower part of transmission actuator ZF No. 6009 298 006.
32 22 ZF transmission actuator Interruption of range change group sensor according to frequency of occurence, check the lower part of transmission actuator, refurbish by component exchange (see attachment) or if necessary
139 exchange complete lower part of transmission actuator ZF No. 6009 298 006.

32 25 ZF transmission actuator / Self adjustment error of range change group check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal diameter (9mm);
transmission sensor in position fast check end position value: (end position_GPS) ought to be:490-590; (end position_GPL) ought to be:80-130. The error is situated in the main transmission if the
140 values lie outside this range. If error occurs sporadically, check the lower part of transmission actuator, refurbish by component exchange (see attachment) or if
necessary exchange complete lower part of transmission actuator ZF No. 6009 298 006.

33 21 ZF transmission actuator Short circuit to positive of splitter group sensor according to frequency of occurence, check the lower part of transmission actuator, refurbish with component exchange (see attachment) or if necessary
141 exchange complete lower part of transmission actuator ZF No. 6009 298 006.
33 20 ZF transmission actuator Short circuit to ground of splitter group sensor according to frequency of occurence, check the lower part of transmission actuator, refurbish with component exchange (see attachment) or if necessary
142 exchange complete lower part of transmission actuator ZF No. 6009 298 006.
33 22 ZF transmission actuator Interruption of splitter group sensor according to frequency of occurence, check the lower part of transmission actuator, refurbish with component exchange (see attachment) or if necessary
143
exchange complete lower part of transmission actuator ZF No. 6009 298 006.

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 Fault code and repair instruction AS-Tronic for EvoBus with Softwareversion V33_4g status:2005-08

EvoBus type of error

EvoBus path of

responsibility
ZF-failure No.

failure
cause of failure/
fault description repair instruction
component

33 25 ZF transmission actuator / Self adjustment error of splitter group sensor check air pressure, (ought to be 8-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and minimal diameter (9mm);
transmission check end position value: (end position_GVS) ought to be:500-620; (end position_GVL) ought to be:70-140. The error is situated in the main transmission if the
144 values lie outside this range. If error occurs sporadically, check the lower part of transmission actuator, refurbish by component exchange (see attachment) or if
necessary exchange complete lower part of transmission actuator ZF No. 6009 298 006.

25 32 ZF transmission Range change group (GP) disengagement shift up to gear 8; check air pressure, (ought to be 7-12 bar); a seperate air reservoir is necessary; check maximum allowable length of air line (4m) and
error minimal diameter (9mm); Check the pressure reduction valve, exchange the valve in case of leakage; Check the tranmission sided air circuit for dirt
comtamination. Check sensor travel signal, record Meßwert_Neu_GP, the measured value should not drift or show signal disturbances after GP shifting. If error
145 occurs sporadically, check the lower part of transmission actuator, refurbish by component exchange (see attachment) or if necessary exchange complete
lower part of transmission actuator ZF No. 6009 298 006. If the measured values are okay there is presumably a damage in the main transmission.

25 30 ZF transmission Changeover error during range change group carry out standstill check R,1,2,3 and N, check air pressure, (ought to be 7-12 bar); a seperate air reservoir is necessary; check maximum allowable length of
(GP) shifting air line (4m) and minimal diameter (9mm); check end position value: (Anschlag_GPS) ought to be 490-590; (Anschlag_GPL) ought to be 80-130. Drive up to
gear 8: record Meßwert_Neu_GP, the measured value should not drift or show signal disturbances after GP shifting. The error is situated in the main
146 transmission if the values lie outside this range. If error occurs sporadically, check the lower part of transmission actuator, refurbish by component exchange
(see attachment) or if necessary exchange complete lower part of transmission actuator ZF No. 6009 298 006.

25 31 ZF transmission Range change group (GP) does not engage carry out standstill check R,1,2,3 and N, check air pressure, (ought to be 7-12 bar); a seperate air reservoir is necessary; check maximum allowable length of
air line (4m) and minimal diameter (9mm); check end position value: (Anschlag_GPS) ought to be 490-590; (Anschlag_GPL) ought to be 80-130. Drive up to
gear 8: record Meßwert_Neu_GP, the measured value should not drift or show signal disturbances after GP shifting. The error is situated in the main
147 transmission if the values lie outside this range. If error occurs sporadically, check the lower part of transmission actuator, refurbish by component exchange
(see attachment) or if necessary exchange complete lower part of transmission actuator ZF No. 6009 298 006.

23 32 ZF transmission Splitter (GV) does not disengage carry out standstill check R,1,2,3 and N, check air pressure, (ought to be 7-12 bar); a seperate air reservoir is necessary; check maximum allowable length of
air line (4m) and minimal diameter (9mm); check end position value: (Anschlag_GVS) ought to be 500-620; (Anschlag_GVL) ought to be 70-140. Drive up to
gear 5: record Meßwert_Neu_GV, the measured value should not drift or show signal disturbances after GV shifting. The error is situated in the main
transmission if the values lie outside this range. If error occurs sporadically , check the lower part of transmission actuator, refurbish by component exchange
148 (see attachment) or if necessary exchange complete lower part of transmission actuator ZF No. 6009 298 006.
The failure can also occour, if there is no grease at the input shaft or hub (clutch disc) → remove the transmission and grease the input shaft, after cleaning,
with Optimol Olista Longtime 3EP. Remove excessive grease!

23 30 ZF transmission, e.g. boring in GV Change over error during splitter shifting carry out standstill check R,1,2,3 and N, check air pressure, (ought to be 7-12 bar); a seperate air reservoir is necessary; check maximum allowable length of
synchronizer ring for take up of (splitter group) air line (4m) and minimal diameter (9mm); Check the clutch disengaging behavior; Check torque build-up (1. gear in manoeuvring mode: taking-along at approx.
the 3 arresting pins is too big 30% clutch travel); defective splitter group synchronizer (unlatch rim worn / damaged); check end position value: (Anschlag_GVS) ought to be 500-620;
149 (Anschlag_GVL) ought to be 70-140. Drive up to gear 5: record Meßwert_Neu_GV, the measured value should not drift or show signal disturbances after GV
shifting. The error is situated in the main transmission if the values lie outside this range. If error occurs sporadically , check the lower part of transmission
actuator, refurbish by component exchange (see attachment) or if necessary exchange complete lower part of transmission actuator ZF No. 6009 298 006.

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 Fault code and repair instruction AS-Tronic for EvoBus with Softwareversion V33_4g status:2005-08

EvoBus type of error

EvoBus path of

responsibility
ZF-failure No.

failure
cause of failure/
fault description repair instruction
component

23 31 ZF transmission Splitter (GV) does not engage carry out standstill check R,1,2,3 and N, check air pressure, (ought to be 7-12 bar); a seperate air reservoir is necessary; check maximum allowable length of
air line (4m) and minimal diameter (9mm); check end position value: (Anschlag_GVS) ought to be 500-620; (Anschlag_GVL) ought to be 70-140. Drive up to
gear 5: record Meßwert_Neu_GV, the measured value should not drift or show signal disturbances after GV shifting. The error is situated in the main
150 transmission if the values lie outside this range. If error occurs sporadically , check the lower part of transmission actuator, refurbish by component exchange
(see attachment) or if necessary exchange complete lower part of transmission actuator ZF No. 6009 298 006.

24 32 ZF transmission Selector cylinder does not disengage carry out standstill check R,1,2,3 and N, check air pressure, (ought to be 7-12 bar); a seperate air reservoir is necessary; check maximum allowable length of
air line (4m) and minimal diameter (9mm); check the air reduction valve, exchange the valve in case of leakage; check the transmission sided air circuit due to
dirt contamination; check end position value: (Anschlag_Gasse1/2) ought to be 70-120; (Anschlag_Gasse3/4) ought to be 500-580). Drive up to gear 4: record
151 Meßwert_Neu_GA, after selection the measured value should not drift or show signal disturbances. The error is situated in the main transmission if the values
lie outside this range. If error occurs sporadically, check the lower part of transmission actuator, refurbish by component exchange (see attachment) or if
necessary exchange complete lower part of transmission actuator ZF No. 6009 298 006.

24 30 ZF transmission change over error during gate selection carry out standstill check R,1,2,3 and N, check air pressure, (ought to be 7-12 bar); a seperate air reservoir is necessary; check maximum allowable length of
procedure air line (4m) and minimal diameter (9mm); check end position value: (Anschlag_Gasse1/2) ought to be 70-120; (Anschlag_Gasse3/4) ought to be 500-580).
Drive up to gear 4: record Meßwert_Neu_GA, after selection the measured value should not drift or show signal disturbances. The error is situated in the main
152 transmission if the values lie outside this range. If error occurs sporadically, check the lower part of transmission actuator, refurbish by component exchange
(see attachment) or if necessary exchange complete lower part of transmission actuator ZF No. 6009 298 006.

153 24 31 ZF transmission Selector cylinder does not engage as failure 151 before
26 32 ZF transmission Main transmission gear does not disengage carry out standstill check R,1,2,3 and N, check air pressure, (ought to be 7-12 bar); a seperate air reservoir is necessary; check maximum allowable length of
air line (4m) and minimal diameter (9mm); check the air reduction valve, exchange the valve in case of leakage; check the transmission sided air circuit due to
dirt contamination; check clutch disengagement behaviour; check end position value: (Anschlag_Gaenge_gerade) ought to be 530-580; (Anschlag_Gaenge
154 ungerade) ought to be 80-120. Drive up to gear 6: record Meßwert_Neu_GE, after shifting the measured value should not drift or show signal disturbances. The
error is situated in the main transmission if the values lie outside this range. If error occurs sporadically, check the lower part of transmission actuator, refurbish
by component exchange (see attachment) or if necessary exchange complete lower part of transmission actuator ZF No. 6009 298 006.

26 31 ZF transmission Main transmission gear does not engage as failure 154 before, also check the transmission brake gradient (Datalogger measurement); in case of defective transmission brake, check necessarily the oil
155 for possible water content.
26 30 ZF transmission Wrong gear shifting in main transmission as failure 154 before
156

31 42 ZF transmission Gate select sensor signal (main transmission) Check the transmission ground connection; Check end position values; test drive up to gear 4, record Meßwert_Neu_GA, after shifting the measured value
leaves engaged position should not drift or show signal disturbances. The error is situated in the main transmission if the values lie outside this range.
157 Component exchanges mostly don' help!

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 Fault code and repair instruction AS-Tronic for EvoBus with Softwareversion V33_4g status:2005-08

EvoBus type of error

EvoBus path of

responsibility
ZF-failure No.

failure
cause of failure/
fault description repair instruction
component

30 42 ZF transmission actuator/ Shift sensor signal (main transmission) leaves Check the transmission ground connection; Check end position values; test drive up to gear 4, record Meßwert_Neu_GA, after shifting the measured value
transmission engaged position during driving should not drift or show signal disturbances. The error is situated in the main transmission if the values lie outside this range.
158 Component exchanges mostly don' help!

32 42 ZF transmission actuator/ Range change group sensor signal leaves Check the transmission ground connection; test drive up to gear 12, record Meßwert_Neu_GP, after shifting the measured value should not drift or show signal
transmission engaged position during driving disturbances. The error is situated in the main transmission if the values lie outside this range. If error occurs sporadically, check the lower part of transmission
159 actuator, refurbish by component exchange (see attachment) or if necessary exchange complete lower part of transmission actuator ZF No. 6009 298 006.

33 42 ZF transmission actuator/ Splitter sensor signal leaves engaged position Check the transmission ground connection; test drive up to gear 12, record Meßwert_Neu_GV, after shifting the measured value should not drift or show signal
transmission during driving disturbances. The error is situated in the main transmission if the values lie outside this range. If error occurs sporadically, check the lower part of transmission
160 actuator, refurbish by component exchange (see attachment) or if necessary exchange complete lower part of transmission actuator ZF No. 6009 298 006.

91 40 EvoBus vehicle Engine does not react on AS-Tronic torque error in on- board computer, check ADM module, check exhaust brake, it gets possibly stuck, check signal of foot brake switch, it gets possibly stuck
163
request
95 42 EvoBus on- board computer CAN error on "Drivers demand engine percent error in on- board computer, check ADM module, check accelerator pedal Alpha_FP and z_kd; ought to be 0-100% then kickdown signal; plug connection
164
torque" (EEC 1) accelerator pedal; test cruise control for function
62 41 EvoBus on- board computer Permanent idle signal check accelerator pedal Low idle signal, ought to be: depression >4%+/- 2%, error in on- board computer, check ADM module, check accelerator pedal
166 Alpha_FP and z_kd; ought to be 0-100% then kickdown signal; plug connection accelerator pedal; test cruise control for function

93 42 EvoBus on- board computer CAN error on "Percent load at current speed" error is set when engine is ongoing, failure No. 27 when engine is off! Error in on- board computer, check ADM module, check accelerator pedal Alpha_FP and
167 signal (EEC2) z_kd; ought to be 0-100% then kickdown signal; plug connection accelerator pedal; test cruise control for function

96 42 EvoBus on- board computer CAN error on "AP low idle switch" or never check accelerator pedal Low idle signal, ought to be: depression >4%+/- 2%, error in on- board computer, check ADM module, check accelerator pedal
168 active "idle signal" Alpha_FP and z_kd; ought to be 0-100% then kickdown signal; plug connection accelerator pedal; test cruise control for function

38 32 ZF transmission actuator Cut- off relay in transmission actuator according to frequency of occurence, exchange upper part of TCU ZF No. 6009 098 002 (Rep.kit), with suitable vehicle specific programming
169 electronic (ECU) does not switch off

38 31 ZF / EvoBus transmission actuator/ electrical no voltage supply at pin 30 or cut - off relay in check voltage supply at transmission actuator between pin 4/5 to pin 16 or 17, ought to be : 20-24V, if voltage < 18,0 V,check chassis side electrical connection
170 system of vehicle transmission actuator electronic (ECU) does and power supply, if voltage is okay exchange upper part of TCU ZF No. 6009 098 002 (Rep.kit), with suitable vehicle specific programming
not switch on
92 42 EvoBus on- board computer CAN error on "Actual engine percent torque" necessary for ISMA, check on- board computer, ADM module, electrical CAN connections
171
signal
86 42 ZF / EvoBus Intarder CAN error on "Retarder lever position" read out error memory of Intarder, check wiring, pedal signal, Intarder lever, if necessary exchange them, if all digital signals are okay exchange Intarder ECU.
172
97 42 EvoBus on- board computer CAN error on "Brake switch" signal (CCVS) check brake pressure switch z_fbr, switch on/ switch off pressure point and behaviour, if there is no foot brake signal when foot brake is used, ISMA calculates
173
like ascent because of the retarding and shifts into gear 1 when vehicle is in standstill

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 Fault code and repair instruction AS-Tronic for EvoBus with Softwareversion V33_4g status:2005-08

EvoBus type of error

EvoBus path of

responsibility
ZF-failure No.

failure
cause of failure/
fault description repair instruction
component

98 42 EvoBus on- board computer CAN error on "Kickdown switch" signal defined switching point: Kickdown z_kd > 97% accelerator pedal, kickdown switch and kickdown function can be integrated in the accelerator pedal or can take
174
place ,by a seperate pressure switch, pay attention to pressure point and adjustment.
60 31 EvoBus electrical system of vehicle Error on "Ignition lock" signal (terminal 15) check voltage supply at transmission actuator, check fuse, ought to be 10A fuse; between pin 1 to pin 16 or 17, ought to be : 20-24V, if voltage < 18,0 V, check
175
chassis side electrical connection and power supply. Transmission actuator exchange don't help!
64 1 ZF / EvoBus transmission actuator/ vehicle System- CAN Busoff error (vehicle CAN) check CAN connections and CAN bridge, ought to be 60Ω; exchange it if necessary ZF No. 0501 212 977; check star point connection , maximum allowable
177 CAN length of CAN line: 3m, if all resistances and CAN connections are okay exchange upper part of TCU ZF No. 6009 098 002 (Rep.kit) vehicle specific
programming must be installed.
64 5 ZF / EvoBus transmission actuator/ vehicle CAN Errorwarning (vehicle CAN) Check the controller, which are connected with the vehicle CAN; check CAN connections and CAN bridge, ought to be 60Ω; exchange it if necessary ZF No.
CAN 0501 212 977; check star point connection , maximum allowable length of CAN line: 3m, if all resistances and CAN connections are okay exchange upper
178 part of TCU ZF No. 6009 098 002 (Rep.kit), vehicle specific programming must be installed. The exchange of the upper part of the transmission actuator
mostly don't help!
64 4 ZF / EvoBus transmission actuator/ vehicle CAN queue overrun check CAN connections and CAN bridge, ought to be 60Ω; exchange it if necessary ZF No. 0501 212 977; check star point connection , maximum allowable
CAN length of CAN line: 3m, take off all CAN paticipants one after another until failure No. 179 is not active any more, exchange defective control unit, if all
179 resistances and CAN connections are okay exchange upper part of TCU ZF No. 6009 098 002 (Rep.kit), with suitable vehicle specific programming

66 10 ZF transmission actuator ECU fault - wrong interrupt OR transmission disconnect main electric current supply or ignition, if error is still existent undertake programming again, if necessary exchange upper part of TCU ZF No. 6009
188 actuator and software not compatible. 098 002 (Rep.kit), vehicle specific programming must be installed.

66 11 ZF transmission actuator Transmission actuator electronic (ECU) fault - as failure 188 before
189
stack watch
66 12 ZF transmission actuator EOL EEPROM parameter out of valid range as failure 188 before
190

66 13 ZF transmission actuator EOL EEPROM parameter checksum error as failure 188 before
191
66 14 ZF transmission actuator ECU fault - EEPROM access failure or as failure 188 before
192
checksum error (only processor 2)
66 44 ZF transmission actuator Transmission actuator electronic (ECU) failure is set when ECU temperature > 125°C, gear oil > 130°C ,oil cooler defective, too little, too much oil, wrong type of oil, turbo charger defective or leaking,
193 temperature too high exhaust pipe system above the transmission actuator is mounted too close or is leaking ( insulation defective)

82 42 EvoBus ABS / EBS brake control Both sources for front axle speed not available front axle speed sensor /ABS/EBS CAN signal, check plug and wiring; check ZF output speed sensor signal, if necessary exchange the ouput speed sensor
194
81 42 EvoBus ABS / EBS brake control CAN error on "Front axle speed" signal (WSI) front axle speed sensor /ABS/EBS CAN signal, check plug and wiring
197
52 42 Evobus ABS / EBS brake control CAN error on "relative wheel speed" signal front axle speed sensor /ABS/EBS CAN signal, check plug and wiring
198
67 3 EvoBus ABS / EBS brake control IES: CAN_MESSAGE timeout: ID512 (ABS / check ABS message, wiring, CAN plug connections; message content: ASR/ABS intervention; system acknowledgement
216
EBS message)

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 Fault code and repair instruction AS-Tronic for EvoBus with Softwareversion V33_4g status:2005-08

EvoBus type of error

EvoBus path of

responsibility
ZF-failure No.

failure
cause of failure/
fault description repair instruction
component

68 3 EvoBus ABS / EBS brake control IES: CAN_MESSAGE timeout: ID513 (ABS / check ABS message, wiring, CAN plug connections; message content: speed front axle/ rear axle, differential speed
217
EBS message)
70 3 EvoBus on- board computer IES: CAN_MESSAGE timeout: ID592 (on- check on- board computer message, wiring; check CAN participants and plug connections, message content:
218 board computer message) Lowidle switch,Kickdown,Tempomatic,Butterfly valve position, Constant throttle position, Service brake, C 3-Speedometer signal, Engine speed signal

71 3 EvoBus on- board computer IES: CAN_MESSAGE timeout: ID593 (on- check on- board computer message, wiring; check CAN participants and plug connections, message content:
219 board computer message) Engine moment desired value, Speed desired value/Tempomatic, drive/brake torque actual value, Engine friction moment
72 3 ZF/EvoBus Intarder IES: CAN_MESSAGE timeout: ID772 check Intarder message, CAN plug and wiring, IT failure memory, message content:
220 (Intarder message) Intarder lever, actual Intarder Moment, max. Intarder moment, in case of no failure on the CAN group, exchange the Intarder ECU
77 3 EvoBus on- board computer IES: CAN_MESSAGE timeout: ID1369 (on- check on- board computer message, wiring; check CAN participants and plug connections, message content:
223 board computer message) actual governed speed, desired idle speed, momentary/absolute max. engine torque

76 3 EvoBus Intarder IES: CAN_MESSAGE timeout: ID1284 check Intarder message, CAN plug and wiring, IT failure memory, message content:
225 (Intarder message) Downshift requirement because of to high temperature during Intarder operation, in case of no failure on the CAN group, exchange the Intarder ECU

66 15 ZF transmission actuator Application error on database OR VEPS-error disconnect main electric current supply or ignition, if error is still existent undertake programming again, if necessary exchange upper part of TCU ZF No. 6009
227 098 002 (Rep.kit), vehicle specific programming must be installed.

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